Ophthalmic lens with segmented ring layers in a functionalized insert

ABSTRACT

This invention discloses various designs for rings and ring segments that make up functionalized layers in a functional layer insert, for incorporation into an ophthalmic lens. The layer insert which can include substrate layers that are intact full rings, segmented rings or a combination of both. Segmented rings may include Arc-Matched and Non Arc-Matched arcuate segments.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority as a Continuation in Partapplication to U.S. patent application Ser. No. 13/401,959 filed Feb.22, 2012, and entitled, “Methods and Apparatus for Functional Insertwith Power Layer” the contents of which are relied upon and incorporatedherein by reference.

FIELD OF USE

This invention describes a functionalized layer insert for an ophthalmicdevice formed from multiple functional layers which are stacked, as wellas, in some embodiments, various designs for rings and ring segmentsthat comprise the functional layers.

BACKGROUND

Traditionally an ophthalmic device, such as a contact lens, anintraocular lens or a punctal plug included a biocompatible device witha corrective, cosmetic or therapeutic quality. A contact lens, forexample, can provide one or more of: vision correcting functionality;cosmetic enhancement; and therapeutic effects. Each function is providedby a physical characteristic of the lens. A design incorporating arefractive quality into a lens can provide a vision corrective function.A pigment incorporated into the lens can provide a cosmetic enhancement.An active agent incorporated into a lens can provide a therapeuticfunctionality. Such physical characteristics are accomplished withoutthe lens entering into an energized state. A punctal plug hastraditionally been a passive device.

More recently, it has been theorized that active components may beincorporated into a contact lens. Some components can includesemiconductor devices. Some examples have shown semiconductor devicesembedded in a contact lens placed upon animal eyes. It has also beendescribed how the active components may be energized and activated innumerous manners within the lens structure itself The topology and sizeof the space defined by the lens structure creates a novel andchallenging environment for the definition of various functionalities.Generally, such disclosures have included discrete devices. However, thesize and power requirements for available discrete devices are notnecessarily conducive for inclusion in a device to be worn on a humaneye.

SUMMARY

Accordingly, the present invention includes a functionalized layerinsert that can be energized and incorporated into an ophthalmic device.The insert can be formed of multiple layers which may have uniquefunctionality for each layer; or alternatively mixed functionality butin multiple layers. The layers may in some embodiments have layersdedicated to the energization of the product or the activation of theproduct or for control of functional components within the lens body.

In some embodiments, the functionalized layer insert may contain a layerin an energized state which is capable of powering a component capableof drawing a current. Components may include, for example, one or moreof: a variable optic lens element, and a semiconductor device, which mayeither be located in the stacked layer insert or otherwise connected toit. Some embodiments can also include a cast molded silicone hydrogelcontact lens with a rigid or formable insert of stacked functionalizedlayers contained within the ophthalmic lens in a biocompatible fashion.

Accordingly, the present invention includes a disclosure of anophthalmic lens layer insert comprising stacked functionalized layerportion designs, as well as various designs for rings and ring segmentsthat comprise the functional layers. In some embodiments, the layerinsert can include substrate layers that are intact full rings,segmented rings or a combination of both. Furthermore, segmented ringsmay include Arc-Matched and Non Arc-Matched arcuate segments.

An insert may be formed from multiple layers in various manners andplaced in proximity to one, or both of, a first mold part and a secondmold part. A reactive monomer mix is placed between the first mold partand the second mold part. The first mold part is positioned proximate tothe second mold part thereby forming a lens cavity with the energizedsubstrate insert and at least some of the reactive monomer mix in thelens cavity; the reactive monomer mix is exposed to actinic radiation toform an ophthalmic lens. Lenses may be formed via the control of actinicradiation to which the reactive monomer mixture is exposed.

DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a three dimensional representation of an insertformed of stacked functional layers which is incorporated within anophthalmic lens mold part.

FIG. 2 illustrates two cross-sectional representations of inserts formedof stacked functional layers incorporated within two different shapedophthalmic lenses.

FIG. 3 illustrates two cross-sectional representations of inserts formedof stacked functional layers incorporated within ophthalmic lenses withdifferent encapsulation parameters.

FIG. 4 illustrates two cross-sectional representations of inserts formedof stacked functional layers with different layer thicknessesincorporated within ophthalmic lenses.

FIG. 5 illustrates a top down view of a one-quarter arc ring segmentcreated with different inner and outer radii, as well as nesting of ringsegments and a full ring composed of ring segments.

FIG. 6 illustrates a top down view of a one-quarter arc ring segmentcreated with matching inner and outer radii, as well as nesting of ringsegments and a full ring composed of ring segments.

FIG. 7 illustrates a top down view of a one-quarter arc ring segmentcreated with partial matching of inner and outer radii, as well asnesting of ring segments and a full ring composed of ring segments.

FIG. 8 illustrates a top down view of various ring segment shapes fromFIGS. 5-7 for comparison purposes.

DETAILED DESCRIPTION OF THE INVENTION

The present invention includes a substrate insert device formed throughthe stacking of multiple functionalized layers. Additionally the presentinvention includes various designs for a wafer including rings and ringsegments that may be used to make up functionalized layers in afunctional layer insert, for incorporation into an ophthalmic lens.

In the following sections detailed descriptions of embodiments of theinvention will be given. The description of both preferred andalternative embodiments are exemplary embodiments only, and it isunderstood that to those skilled in the art that variations,modifications and alterations may be apparent. It is therefore to beunderstood that said exemplary embodiments do not limit the scope of theunderlying invention.

GLOSSARY

In this description and claims directed to the presented invention,various terms may be used for which the following definitions willapply:

Active Lens Insert: as used herein refers to an electronic orelectromechanical device with controls based upon logic circuits.

Arc-matched (or arc matching): as used herein refers to the design of aRing Segment which includes an identical External Radius and InternalRadius, such that the curvature of the External Arc matches thecurvature of the Internal Arc. Arc matching is used to efficiently nestRing Segments on a Wafer, maximizing wafer utilization.

Dicing Street Width: as used herein refers to the width of a thinnon-functional space between integrated circuits on a Wafer, where a sawor other device or method can safely cut the Wafer into individual Diewithout damaging the circuits.

Die: as used herein refers to a block of semiconducting material, onwhich a given functional circuit is fabricated. Die are created on andcut from a Wafer.

Energized: as used herein refers to the state of being able to supplyelectrical current to or to have electrical energy stored within.

Energy: as used herein refers to the capacity of a physical system to dowork. Many uses within this invention may relate to the said capacitybeing able to perform electrical actions in doing work.

Energy Source: as used herein refers to device capable of supplyingEnergy or placing a biomedical device in an Energized state.

External Arc: as used herein refers to the external or convex edge of aRing Segment, which is a portion of the circumference of the circledefined by the External Radius.

External Radius: as used herein refers to the radius of the circle thatdefines the external edge of a Full Ring or Ring Segment. The ExternalRadius determines the curvature of the External Arc.

Full Ring: as used herein refers to one complete ring-shaped layer in aFunctionalized Layer Insert. A Full Ring may be comprised of multipleRing Segments or may be one Intact Ring.

Functionalized: as used herein refers to making a layer or device ableto perform a function including for example, energization, activation,or control.

Functionalized Layer Insert: as used herein refers to an insert for anophthalmic device formed from multiple functional layers which arestacked. The multiple layers may have unique functionality for eachlayer; or alternatively mixed functionality but in multiple layers. Insome preferred embodiments, the layers can be assembled into rings.

Intact Ring: as used herein refers to one complete ring-shaped layer ina Functionalized Layer Insert which is made of a single intact Die.

Internal Arc: as used herein refers to the internal or concave edge of aRing Segment. The Internal Arc may, in some embodiments, be a single arcsegment, the curvature of which is determined by the Internal Radius. Inother embodiments the Internal Arc may be comprised of multiple arcsegments of different curvatures, defined by different Internal Radii.

Internal Radius: as used herein refers to the radius of the circle thatdefines the internal edge or a portion of the internal edge of a FullRing or Ring Segment. The Internal Radius determines the curvature ofthe Internal Arc.

Lens: refers to any ophthalmic device that resides in or on the eye.These devices can provide optical correction or may be cosmetic. Forexample, the term lens can refer to a contact lens, intraocular lens,overlay lens, ocular insert, optical insert or other similar devicethrough which vision is corrected or modified, or through which eyephysiology is cosmetically enhanced (e.g. iris color) without impedingvision. In some embodiments, the preferred lenses of the invention aresoft contact lenses are made from silicone elastomers or hydrogels,which include but are not limited to silicone hydrogels, andfluorohydrogels.

Mold: refers to a rigid or semi-rigid object that may be used to formlenses from uncured formulations. Some preferred molds include two moldparts forming a front curve mold part and a back curve mold part.

Power: as used herein refers to work done or energy transferred per unitof time.

Ring Segment: as used herein refers to one Die which may be combinedwith other Die to construct a Full Ring. As used in this invention, aRing Segment is generally flat and is formed in an arcuate shape.

Stacked: as used herein means to place at least two component layers inproximity to each other such that at least a portion of one surface ofone of the layers contacts a first surface of a second layer. In someembodiments, a film, whether for adhesion or other functions may residebetween the two layers that are in contact with each other through saidfilm.

Substrate insert: as used herein refers to a formable or rigid substratecapable of supporting an Energy Source within an ophthalmic lens. Insome embodiments, the Substrate insert also supports one or morecomponents.

Wafer: as used herein refers to a thin slice of semiconductor material,such as silicon crystal, used in the fabrication of integrated circuitsand other microdevices. The wafer serves as the substrate formicroelectronic devices built in and over the wafer and undergoes manymicrofabrication process steps.

Apparatus

Referring now to FIG. 1, demonstrated as item 100 is a three dimensionalrepresentation of some embodiments of a fully formed ophthalmic lensusing a stacked layer substrate insert formed as a functionalized layerinsert 110. The representation shows a partial cut out from theophthalmic lens to realize the different layers present inside thedevice. A body material 120 is shown in cross section of theencapsulating layers of the substrate insert. The body material 120 iscontained fully within and extends around the entire circumference ofthe ophthalmic lens. It may be clear to one skilled in the arts that theactual functionalize layer insert 110 may comprise a full annular ringor other shapes that still may reside within the constraints of the sizeof a typical ophthalmic lens.

Layers 130, 131 and 132 illustrate three of numerous layers that may befound in a functionalized layer insert 110. In some embodiments, asingle layer may include one or more of: active and passive componentsand portions with structural, electrical or physical propertiesconducive to a particular purpose.

In some embodiments, a layer 130 may include an energization source,such as, for example, one or more of: a battery, a capacitor and areceiver within the layer 130. Item 131 then, in a non limitingexemplary sense, may comprise microcircuitry in a layer that detectsactuation signals for an active lens insert 140. In some embodiments, apower regulation layer 132, may be included that is capable of receivingpower from external sources, charging the battery layer 130 andcontrolling the use of battery power from layer 130 when the lens is notin a charging environment. The power regulation layer 132 may alsocontrol signals to an exemplary active lens insert 140 in the centerannular cutout of the functionalized layer insert 110.

In general, according to this embodiment, a functionalized layer insert110 is embodied within an ophthalmic lens via automation which places anenergy source a desired location relative to a mold part used to fashionthe lens.

The size, shape, and stacking structure of the die that may be used toform layers such as 130, 131 and 132 in a functionalized layer insert110 is influenced by several factors, as shown in FIGS. 2, 3 and 4.

FIG. 2 illustrates the effect of lens shape on the design of afunctionalized layer insert. The base curve, diameter, and thickness ofan ophthalmic lens define a maximum size and shape of an includedfunctionalized layer insert. FIG. 2 shows, as one example, the impact ofdifferent base curves. Item 200A depicts a cross sectional view of aportion of an ophthalmic lens 205A with more curvature than theophthalmic lens 205B, depicted in item 200B, which is flatter. Theflatter lens 205B can accommodate a functionalized layer insert 201B ofgreater width 202B, as compared to the narrower width 202A of afunctionalized layer insert 201A that fits within lens 205A havinggreater base curvature. It should be apparent that a lens of smallerdiameter (203A indicates a lens diameter) would limit the width of afunctionalized layer insert while a lens with larger diameter wouldaccommodate a wider functionalized layer insert. Likewise, a lens ofless thickness (204A indicates a lens thickness) would limit the numberof layers in a functionalized layer insert as well as the width of afunctionalized layer insert, while a thicker lens might support morelayers and layers of greater width.

FIG. 3 illustrates the effect of encapsulation parameters on the designof a functionalized layer insert. Encapsulation parameters, such as, byway of non-limiting example, maintaining a minimum 100 micron thicknessbetween the edge of a die and the outer edge of a lens, affect the sizeand shape of a functionalized layer insert and therefore the size andshape of individual layers. Item 300A depicts a cross-sectional view ofa portion of an ophthalmic lens 305A with a functionalized layer insert301A and encapsulation boundary 303A. The ophthalmic lens 305B depictedin item 300B includes a functionalized layer insert 301B and arelatively wider encapsulation boundary 303B as compared to boundary303A which is narrower. It can be seen that the wider encapsulationboundary 303B necessitates that the functionalized layer insert 301B benarrower in width 302B as compared to the functionalized layer insert301A with width 302A.

Depicted in FIG. 4 is the effect of functional layer thickness on thedesign of a functionalized layer insert. Item 400A represents across-sectional view of a portion of an ophthalmic lens 405A with afunctionalized layer insert 401A including three layers with material,such as, for example, insulating layers, between the functional layers.A functionalized layer insert may contain more or less than threelayers. The ophthalmic lens 405B depicted in item 400B includes afunctionalized layer insert 401B with relatively thicker layers 402B ascompared to the layers 402A in the functionalized layer insert 401Awhich are thinner. The lens curvature in these two examples allows thewidth of the bottom layers 402A and 402B to remain the same. However, itcan be seen that the increased height of the functionalized layer insert401B as compared to 401A, combined with the lens curvature, causes thetop layer 402A to be limited in width. The thickness of each functionallayer impacts other dimensions, such as functional layer width, thatwill fit within the required lens and encapsulation parameters. Thickerlayers within the functionalized layer insert will be more restricted inother dimensions, such as width, in order to remain within the confinesof the lens geometry.

Ring Segment Design

In the embodiments depicted in this invention, each layer within afunctionalized layer insert is in the shape of a ring, either formed ofan intact ring-shaped die or of multiple ring segments. Rings or ringsegments are manufactured on wafers, from which they are subsequentlycut. Ring segments allow significantly more efficient use of wafermaterial than full rings, as will be demonstrated in FIGS. 5-8.Therefore, the decision to produce an intact ring versus a ring composedof multiple ring segments may be based, in part, on the costs of the diesubstrate and manufacturing processes. Other factors in the decisionbetween intact rings versus multiple ring segments include the functionsto be performed on a specific layer within the functionalized layerinsert and the advantage of structural stability provided when one ormore intact rings are included in a functionalized layer insert. Oneexample of a function that may require a full ring is a radio frequencyantennae positioned around the full circumference of a die. Anotherexample is an interconnect layer used to route signals between ringsegments below it and ring segments above it, wherein the connectionsneed to span different locations around the circumference of thefunctionalized layer insert.

Factors contributing to die cost may include, by way of non-limitingexample, the cost of the substrate material and the number of steps, andtherefore the time cost, associated with the fabrication process. Diecreated on an inexpensive substrate, such as, for example, ceramic orKapton®, with relatively minimal fabrication steps may be produced in aless efficient layout such as full rings. Full rings result insignificant waste of wafer material, but low cost material andfabrication may make production of full rings feasible for some layerswithin a functionalized layer insert. Alternatively, die created on anexpensive substrate, such as, for example, silicon, with relatively morecomplex fabrication effort including many steps and details, may bearchitected in multiple ring segments such that the number of ringscreated from a single wafer is optimized. FIGS. 5-8 will show thatspecific ring segment designs significantly improve the nesting ofrings, and therefore the ability to efficiently arrange ring segments ona wafer for optimal wafer utilization.

Other factors are considered when optimizing the layout of die, or ringsegments, on wafers. For example, photo etching of die, if necessary aspart of the fabrication method, is a process typically performed inrectangular blocks on a wafer. When photo etching is required, a linearlayout of ring segments is more efficient than a radial layout. Dicingstreet width, the non-functional space between die on a wafer, affectsoptimization and layout. Dicing street width may be determined, forexample, by the specific technology or tools used to cut the die fromthe wafer at the end of the manufacturing process. Edge offset isanother parameter affecting die layout. Edge offset is the minimumdistance between the edge of a die and the outer edge of a wafer.

When designing the layout of ring segments on a wafer, the shape of eachindividual ring segment significantly impacts optimization of waferutilization. Ring segment design may be grouped into three generalcategories: no arc matching (FIG. 5), full arc matching (FIG. 6), andpartial arc matching (FIG. 7). Different ring segment designs may becombined within one layer of a functionalized layer insert, as well asin different layers of a functionalized layer insert.

Referring now to FIG. 5, depicted is an example of ring segmentsdesigned with no arc matching, showing one-quarter ring segments createdwith different interior and exterior radii. The external radius definedby circle 501 is greater than the internal radius defined by circle 502,and therefore external arc 503 has less curvature than internal arc 504.Ring segment 505 therefore has different internal and external radii.Item 506 demonstrates that ring segments 505 do not nest efficiently,with significant gaps between the individual die, which results in wastewhen producing die on a wafer. Item 507 reveals that four ring segments505 may be combined to produce a full ring with a circular interioredge.

Referring now to FIG. 6, an example of full arc matching is shownincluding one-quarter ring segments created with identical interior andexterior radii. The external radius defined by circle 601 is identicalto the internal radius defined by circle 602, which is offset ratherthan reduced in size to define the shape of ring segment 605. Thereforeexternal arc 603 and internal arc 604 have identical curvature. It isshown in item 606 that ring segments 605 can be precisely nested,leaving only a small dicing street width required for cutting theindividual die 605 from the wafer. This design significantly minimizeswaste when producing die on a wafer. A full ring composed of four ringsegments 605 is depicted in item 607. Since the full arc matching designresults in die 605 that are slightly tapered on the ends, the interioredge of the resulting ring in item 607 is not perfectly circular.

Referring now to FIG. 7, a partial arc matching design is depicted withone-quarter ring segments created with a combination of threecurvatures. Item 708 provides a close up view of the elements definingthe shape of ring segment 705. In item 708, the outline has been removedfrom ring segment 705 so that the defining shapes may be more clearlyseen. The curvature of external arc 703 is determined by the radius ofcircle 701. Internal arc 704 is comprised of two different curvatures.Circle 702, denoted with a dashed line, has a smaller radius than circle701 and defines the center portion 704A of the internal arc 704. Circle709, denoted with an alternating dash-dot line, has a radius identicalto circle 701. Circle 709 is positioned such that it intersects circle702 towards the ends of ring segment 705. Circle 709 therefore definesthe curvature of the two end portions 704B of the internal arc 704. Thishybrid design for internal arc 704 maximizes the active area availableon the die while including partial arc matching near the ends of ringsegment 705 to improve nesting and therefore efficiency of die layout ona wafer. Item 706 shows the nesting of ring segments 705, wherein theidentical radii of circles 701 and 709 in the design of ring segments705 provide for close nesting alignment at the ends of the die. Item 707shows a full ring composed of four ring segments 705. The design of die705 includes tapered ends, resulting in a ring with an interior edgewhich is not perfectly circular, shown in item 707.

Referring now to FIG. 8, a comparison of the ring segments described inFIGS. 5-7 is shown. Item 801 shows the nesting of ring segments 505created with no arc matching. Item 802, likewise depicts nesting of fullarc-matched ring segments 605, and item 803, partial arc-matched ringsegments 705. Item 802 clearly shows optimal nesting of full arc-matchedring segments 605. It is also evident from item 803 that partialarc-matched ring segments 705 nest more efficiently than ring segments505 with no arc matching.

Item 804 compares the area of fully arc-matched ring segment 605 withring segment 505, designed with no arc matching. When 605 is overlaidupon 505, it can be seen that 605 has tapered ends, reducing the surfacearea available on the fully arc-matched die 605. Although full arcmatching supports the most efficient layout of ring segments on a wafer,it does so at the cost of less surface area on each ring segment.

Item 805 similarly compares the area of partially arc-matched ringsegment 705 with ring segment 505, designed with no arc matching. When705 is overlaid upon 505, it is again evident that 705 has tapered ends,but less than seen in the comparison of item 804. The surface areaavailable on the partially arc-matched ring segment 705 is somewhatreduced as compared to ring segment 505 with no arc matching.

Finally, item 806 compares fully arc-matched ring segment 605 withpartially arc-matched ring segment 705. Although both have tapered ends,when 605 is overlaid upon 705 it is shown that partially arc-matchedring segment 705 has a slightly greater surface area. Partial arcmatching is a hybrid solution which preserves more surface area on aring segment while adjusting the curvature near the ends of the ringsegment for improved nesting in the layout of ring segments on a wafer.Partial arc matching may be used, by way of non-limiting example, tocreate battery die where the active area for the battery is notsacrificed but the ring segment ends are slightly narrowed, improvingmanufacturing efficiency without impacting functionality.

CONCLUSION

The present invention, as described above and as further defined by theclaims below, provides various designs for rings and ring segments thatmake up the functionalized layers in a functional layer insert, forincorporation into an ophthalmic lens.

1. An active lens insert for an ophthalmic lens comprising: arcuateshape ring segments assembled into substrate layers with one or both ofelectrical and logical Functionality; wherein the size, shape andstacking structure of each of the annular shaped substrate layers isbased on the thickness around an optical zone of the ophthalmic lens;electrical interconnections between substrate layers; and wherein theactive lens insert is encapsulated with one or more materials that maybe bonded within the body material of a molded ophthalmic lens.
 2. Theactive lens insert of claim 1, wherein the substrate functional layersare adhered to insulating layers forming a stacked feature.
 3. Theactive lens insert of claim 1, wherein the arcuate shaped ring segmentsare cut from a wafer.
 4. The active lens insert of claim 1, wherein oneor more of the arcuate shaped ring segment(s) has one or both taperedends.
 5. The active lens insert of claim 1, wherein the arcuate ringsegments comprise Arc Matched sections.
 6. The active lens insert ofclaim 1, wherein two or more arcuate ring segments can form a full ring.7. The active lens insert of claim 1, wherein the design of the arcuatering segments is based on factors comprising wafer optimization.
 8. Theactive lens insert of claim 7, wherein the design of the arcuate ringsegments is further based on surface area maximization of the ringwithin the active lens insert.
 9. The active lens insert of claim 1,wherein the arcuate ring segments are non-arc matched segments.
 10. Theactive lens insert of claim 1, wherein the arcuate ring segmentscomprise both Arc Matched segments and non-arc matched segments.
 11. Theactive lens insert of claim 1, wherein the substrate functional layersinclude both said assembled ring substrate layers from the arcuate shapering segments and intact full ring segments.
 12. The active lens insertof claim 10, wherein the intact full ring substrate layer comprises ametallic layer which functions as an antenna.
 13. The active lens insertof claim 1, wherein the size, shape and stacking structure of each ofthe annular shaped substrate layers is further based on the base curveof an ophthalmic lens.
 14. The active lens insert of claim 1, whereinthe size, shape and stacking structure of each of the annular shapedsubstrate layers is further influenced by the diameter of an ophthalmiclens.
 15. The active lens insert of claim 1, wherein the size, shape andstacking structure of each of the annular shaped substrate layers isfurther influenced by encapsulation parameters of the active lensinsert.
 16. The active lens insert of claim 1, wherein the substratelayers comprise silicon based wafer layers.
 17. The active lens insertof claim 1, wherein the substrate layers comprise ceramic based waferlayers.
 18. The active lens insert of claim 1, wherein the substratelayers comprise Kapton® based wafer layers.